ABB ACS580-01 drives User manual

ABB general purpose drives

Hardware manual

ACS580-01 drives

(0.75 to 250 kW, 1.0 to 350 hp)

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Hardware manual

ACS580-01 drives

(0.75 to 250 kW, 1.0 to 350 hp)

3AXD50000044794 Rev A

EN

EFFECTIVE: 2017-05-31

1. Safety instructions

Table of contents

4. Mechanical installation

6. Electrical installation

Table of contents 5

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

External control connection terminals, frames R1…R5 . . . . . . . . . . . . . . . . . . . . . . . . . . 35

External control connection terminals, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Control panel door mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Locations of the labels on the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Safety

6 Table of contents

Unpacking and examining delivery, frames R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Frames R1 and R2 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Unpacking and examining delivery, frames R3…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Unpacking and examining delivery, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Frame R5 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Unpacking and examining delivery, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Frame R6 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Frame R7 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Frame R8 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Frame R9 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Installing the drive vertically, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Install the cable box, frames R1…R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Installing the drive vertically, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Installing the drive vertically, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Installing the drive vertically side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Installing the drive horizontally, frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5. Planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . 79

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 80

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Protecting the drive and the input power and motor cables against thermal overload . . . 81

Table of contents 7

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Implementing the undervoltage control (power-loss ride-through) . . . . . . . . . . . . . . . . . . . . . 82

Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Limiting relay output maximum voltages at high installation altitudes . . . . . . . . . . . . . . . . . . . 86

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Brake resistor assembly for R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Checking the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . 91

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Connection procedure, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Default I/O connection diagram (ABB standard macro) . . . . . . . . . . . . . . . . . . . . . . . . . 117

Control cable connection procedure R1…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Reinstalling cover, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8 Table of contents

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Recommended annual actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Recommended maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R5…R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Replacing the main cooling fans, IP21 and IP55 (UL Type 1 and UL Type 12)

frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Replacing the auxiliary cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 . . . . . . . . . . . . 150

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 . . . . . . . . . . . . . . . . . 151

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4 . . . . . . . . . . . . . . . . . 152

Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 . . . . . . 153

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Replacing the battery in the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Control panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

9. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Ambient temperature derating, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Ambient temperature derating, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

uR and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Table of contents 9

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Cooling air flow, heat dissipation and noise for stand-alone drives . . . . . . . . . . . . . . . . 176

Cooling air flow and heat dissipation for flange mounting (option +C135) . . . . . . . . . . . 177

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Brake resistor connection data for frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Compliance with the European ROHS II Directive 2011/65/EU . . . . . . . . . . . . . . . . . . . 196

Compliance with the European Machinery Directive 2006/42/EC 2nd Edition –

June 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Compliance with the EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Frame R1, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Frame R1, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Frame R2, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Frame R2, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Frame R3, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Frame R3, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Frame R4, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Frame R4, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

10 Table of contents

Frame R5, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Frame R5, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Frame R6, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Frame R6, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Frame R7, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Frame R7, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Frame R8, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Frame R8, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Frame R9, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Frame R9, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

11. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Resistor braking, frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Resistor braking, frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

12. Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Connection with internal +24 V DC power supply, single line . . . . . . . . . . . . . . . . . . . . 234

Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Table of contents 11

13. Optional I/O extension modules

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

CHDI-01 115/230 V digital input extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) . . . . . . . . 256

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC

interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

14. Common mode and du/dt filters

Content of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Common mode filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 275

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 275

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

12 Table of contents

Safety instructions 13

1

Safety instructions

Contents of this chapter

This chapter contains the safety instructions which you must obey when you install

and operate the drive and do maintenance on the drive. If you ignore the safety

instructions, injury, death or damage can occur.

Use of warnings and notes in this manual

Warnings tell you about conditions which can cause injury or death, or damage to the

equipment. They also tell you how to prevent the danger. Notes draw attention to a

particular condition or fact, or give information on a subject.

The manual uses these warning symbols:

Electricity warning tells about hazards from electricity which can cause

injury or death, or damage to the equipment.

General warning tells about conditions, other than those caused by

electricity, which can cause injury or death, or damage to the equipment.

Electrostatic sensitive devices warning tells you about the risk of

electrostatic discharge which can cause damage to the equipment.

14 Safety instructions

General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive and do maintenance work

on it.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• Use safety shoes with a metal toe cap to avoid foot injury. Wear protective gloves

and long sleeves. Some parts have sharp edges.

• Handle the drive carefully.

•Frames R

5…R9: Lift the drive with a lifting device. Use the lifting eyes of the

drive.

•Frames R

5…R9: Do not tilt the drive. The drive is heavy and its center of

gravity is high. An overturning drive can cause physical injury.

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,

remain hot for a while after disconnection of the electrical supply.

• Keep the drive in its package or protect it otherwise from dust and burr from

drilling and grinding until you install it.

• Protect also the installed drive against dust and burr. Electrically conductive

debris inside the drive may cause damage or malfunction.

• Vacuum clean the area below the drive before the start-up to prevent the drive

cooling fan from drawing the dust inside the drive.

• Do not cover the air inlet and outlet when the drive runs.

• Make sure that there is sufficient cooling. See sections Checking the installation

site on page 44 and Losses, cooling data and noise on page 176 for more

information.

• Before you connect voltage to the drive, make sure that the drive covers are on.

Keep the covers on during the operation.

• Before you adjust the drive operation limits, make sure that the motor and all

driven equipment can operate throughout the set operation limits.

Safety instructions 15

• Before you activate the automatic fault reset or automatic restart functions of the

drive control program, make sure that no dangerous situations can occur. These

functions reset the drive automatically and continue operation after a fault or

supply break. If these functions are activated, the installation must be clearly

marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS

MACHINE STARTS AUTOMATICALLY”.

• The maximum number of drive power-ups is five in ten minutes. Too frequent

power-ups can damage the charging circuit of the DC capacitors.

• If you have connected safety circuits to the drive (for example, emergency stop

and Safe torque off), validate them at the start up. For the validation of the Safe

torque off, see ACS580 standard control program firmware manual

(3AXD50000016097 [English]). For the validation of other safety circuits, see the

instructions provided with them.

Note:

• If you select an external source for start command and it is on, and the start

command is level-triggered, the drive will start immediately after fault reset. See

parameters 20.02 Ext1 start trigger type and 20.07 Ext2 start trigger type in

ACS580 standard control program firmware manual (3AXD50000016097

[English]).

• When the control location is not set to Local (text Local is not shown on the top

row of the panel and parameter 19.17 Local control disable has value Disabled),

the stop key on the control panel will not stop the drive.

• Frames R1…R5 are not field repairable. Do not attempt to repair a malfunctioning

drive; contact your local representative for replacement.

Frames R1…R9 can be repaired by authorized persons.

16 Safety instructions

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work

These warnings are for all personnel who do work on the drive, motor cable or motor.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur. If you are not a qualified electrician, do

not do electrical installation or maintenance work. Go through these steps before you

begin any installation or maintenance work.

1. Clearly identify the work location.

2. Disconnect all possible voltage sources.

• Open the main disconnector at the power supply of the drive.

• Make sure that reconnection is not possible. Lock the disconnector to open

position and attach a warning notice to the disconnector.

• Disconnect any external power sources from the control circuits before you do

work on the control cables.

• After you disconnect the drive, always wait for 5 minutes to let the

intermediate circuit capacitors discharge before you continue.

3. Protect any other energized parts in the work location against contact.

4. Take special precautions when close to bare conductors.

5. Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive input power terminals (L1, L2,

L3) and the grounding terminal (PE) is close to 0 V.

• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)

and the grounding terminal (PE) is close to 0 V.

6. Install temporary grounding as required by the local regulations.

7. Ask for a permit to work from the person in control of the electrical installation

work.

Safety instructions 17

 Additional instructions and notes

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• If you install the drive on an IT system (an ungrounded power system or a high-

resistance-grounded [over 30 ohms] power system), disconnect the ground-to-

phase varistor; otherwise the varistor circuit can be damaged. See page 92.

• If you install the drive on an IT system (an ungrounded power system or a high-

resistance-grounded [over 30 ohms] power system), disconnect the internal EMC

filter; otherwise the system will be connected to ground potential through the EMC

filter capacitors. This can cause danger or damage the drive. See page 91.

Note: Disconnecting the internal EMC filter increases the conducted emission

and reduces the drive EMC compatibility considerably. See section EMC

compatibility and motor cable length on page 185.

• If you install the drive on a corner-grounded TN system, disconnect the internal

EMC filter; otherwise the system will be connected to ground potential through the

EMC filter capacitors. This will damage the drive. See page 93.

Note: Disconnecting the internal EMC filter increases the conducted emission

and reduces the drive EMC compatibility considerably. See section EMC

compatibility and motor cable length on page 185.

• Use all ELV (extra low voltage) circuits connected to the drive only within a zone

of equipotential bonding, that is, within a zone where all simultaneously

accessible conductive parts are electrically connected to prevent hazardous

voltages appearing between them. You can accomplish this by a proper factory

grounding, that is, make sure that all simultaneously accessible conductive parts

are grounded to the protective earth (PE) bus of the building.

• Do not do insulation or voltage withstand tests on the drive or drive modules.

Note:

• The motor cable terminals of the drive are at a dangerous voltage when the input

power is on, regardless of whether the motor is running or not.

• The DC and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a

dangerous voltage.

• External wiring can supply dangerous voltages to the terminals of relay outputs

(RO1, RO2 and RO3).

• The Safe torque off function does not remove the voltage from the main and

auxiliary circuits. The function is not effective against deliberate sabotage or

misuse.

18 Safety instructions

WARNING! Use a grounding wrist band when you handle the printed circuit

boards. Do not touch the boards unnecessarily. The boards contain

components sensitive to electrostatic discharge.

 Grounding

These instructions are for all personnel who are responsible for the electrical

installation, including the grounding of the drive.

WARNING! Obey these instructions. If you ignore them, injury or death, or

equipment malfunction can occur, and electromagnetic interference can

increase.

• If you are not a qualified electrician, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment to the protective

earth (PE) bus of the power supply. This is necessary for the personnel safety.

Proper grounding also reduces electromagnetic emission and interference.

• In a multiple-drive installation, connect each drive separately to the protective

earth (PE) bus of the power supply.

• Make sure that the conductivity of the protective earth (PE) conductors is

sufficient. See section Selecting the power cables on page 72. Obey the local

regulations.

• Connect the power cable shields to the protective earth (PE) terminals of the

drive.

• Make a 360° grounding of the power and control cable shields at the cable entries

to suppress electromagnetic disturbances.

Note:

• You can use power cable shields as grounding conductors only when their

conductivity is sufficient.

• Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch

current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed

protective earth (PE) connection. In addition,

• install a second protective earth conductor of the same cross-sectional area

as the original protective earthing conductor,

or

• install a protective earth conductor with a cross-section of at least 10 mm

2

Cu

or 16 mm

2

Al,

or

• install a device which automatically disconnects the supply if the protective

earth conductor breaks.

Safety instructions 19

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

These are additional warnings concerning permanent magnet motor drives. The other

safety instructions in this chapter are also valid.

WARNING! Obey these instructions. If you ignore them, injury or death and

damage to the equipment can occur.

• Do not work on a drive when a rotating permanent magnet motor is connected to

it. A rotating permanent magnet motor energizes the drive including its input

power terminals.

Before installation, start-up and maintenance work on the drive:

• Stop the motor.

• Disconnect the motor from the drive with a safety switch or by other means.

• If you cannot disconnect the motor, make sure that the motor cannot rotate during

work. Make sure that no other system, like hydraulic crawling drives, can rotate

the motor directly or through any mechanical connection like felt, nip, rope, etc.

• Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive output terminals (T1/U, T2/V,

T3/W) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive input power terminals (L1, L2,

L3) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and

the grounding (PE) terminal is close to 0 V.

• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).

Connect the output terminals together as well as to the PE.

Start-up and operation:

• Make sure that the operator cannot run the motor over the rated speed. Motor

overspeed causes overvoltage that can damage or destroy the capacitors in the

intermediate circuit of the drive.

20 Safety instructions

General safety in operation

These instructions are for all personnel that operate the drive.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• Do not control the motor with the disconnector at the drive power supply; instead,

use the control panel start and stop keys or commands through the I/O terminals

of the drive.

• Give a stop command to the drive before you reset a fault. If you have an external

source for the start command and the start is on, the drive will start immediately

after the fault reset, unless you configure the drive for pulse start. See the

firmware manual.

• Before you activate automatic fault reset functions of the drive control program,

make sure that no dangerous situations can occur. These functions reset the

drive automatically and continue operation after a fault.

Note: When the control location is not set to Local, the stop key on the control panel

will not stop the drive.

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ABB ACS580-01 drives User manual

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